Cable integrated solar inverter

ABSTRACT

Systems for converting a standard direct current (DC) power from solar panels into a rectified DC power signal for further conversion into alternating current (AC) power are described herein. In some example embodiments, the systems may include distributed power converters and a grid interface unit connected by a trunk cable. In some example embodiments, the power converters may be embedded in the trunk cable.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. non-provisional patentapplication Ser. No. 15/383,647, entitled “Cable Integrated SolarInverter” and filed on Dec. 19, 2016, which claims priority fromprovisional U.S. Application No. 62/269,754, entitled “Cable IntegratedSolar Inverter” and filed on Dec. 18, 2015, each of which is hereinincorporated by reference in its entirety.

BACKGROUND

Photovoltaic (PV) cells are currently used to harvest solar energy foruse in both commercial and residential environments. To enable morewidespread adoption of solar power, however, it is important to minimizethe cost per watt for the power harvested. This requires all elements ofa solar power system to be designed with both cost and system energyrequirements taken into account. As solar power systems comprise severalcomponents in addition to the PV cell, development of these componentsalso affects the evolution of the entire solar power system.

In order to produce power useable for most purposes, the direct current(DC) produced by a PV cell must be converted to alternating current (AC)having the frequency of the local utility. This conversion is typicallyaccomplished by an inverter. A stand-alone inverter is used in totallyisolated systems that normally do not interface with the utility grid.More sophisticated inverters convert the DC to AC at the utilityfrequency and ensure maintaining the AC inverter output in phase withthe utility grid AC phase.

As the DC to AC conversion of power harvested from PV cells is anecessary function of solar power systems, there is on-going need in theart to reduce the cost associated with inverter systems, theirinstallation, and long-term maintenance.

BRIEF SUMMARY

Various embodiments of the present invention are directed to an improvedsolar inverter system for generating AC power from photovoltaic solarpanels or other DC power sources. In various embodiments, a cableintegrated solar inverter is provided for converting DC power from solarmodules to AC power for supplying a grid. In one embodiment, powerconverter cartridges are integrated into trunk cable and connected tosolar panels. The power converter cartridges are connected in series viathe trunk cable, which then provides the combined output from theplurality of power converters to a grid interface unit. In oneembodiment, the grid interface unit receives a rectified (half-sine)wave and converts the rectified wave into a pure AC signal. According tovarious embodiments, the grid interface unit may include fault detectionsystems, monitoring systems, synchronization systems, unfoldingcircuitry, interface and communication circuitry and/or the like.

Particular embodiments of the subject matter described herein can beimplemented so as to realize one or more of the following advantages:allow for embedding and/or incorporating power converters and/orconverter circuitry within a cabling system and for more efficient powerconversion from solar energy systems; reduce the cost and resourcesrequired for installing and maintaining solar energy systems; provide aneasy to service system improving the user experience of customers andservice personnel; eliminate unnecessary service interruptions; andprovide a more efficient and improved optimization process andcapabilities.

The details of one or more embodiments of the subject matter describedherein are set forth in the accompanying drawings and the descriptionbelow. Other features, aspects, and advantages of the subject matterwill become apparent from the description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1A shows a residential environment having a photovoltaic powersystem according to one embodiment;

FIG. 1B is shows a schematic of a cable integrated solar inverter systemaccording to one embodiment;

FIG. 2A shows an isometric view of a power converter cartridge andhousing in which the power converter cartridge is detached from thehousing according to one embodiment;

FIG. 2B shows an isometric view of the power converter cartridge andhousing of FIG. 2A in which the power converter cartridge is secured tothe housing;

FIG. 3 shows isometric view of a cable integrated power converteraccording to another embodiment;

FIG. 4A shows a plan view of cable integrated power converter accordingto yet another embodiment;

FIG. 4B shows a plan view of cable integrated power converter accordingto yet another embodiment;

FIG. 5A is an exemplary schematic diagram of a cabling system accordingto one embodiment;

FIG. 5B depicts an exemplary electrical signal transformation at anexemplary unfolding bridge according to one embodiment;

FIG. 6 is an exemplary control system block diagram according to oneembodiment;

FIG. 7 is an exemplary schematic diagram of a cabling system accordingto another embedment;

FIG. 8A depicts an exemplary combined synchronization and serialcommunication electrical signal; and

FIG. 8B depicts a serial representation of an exemplary combinedsynchronization and serial communication electrical communicationpacket.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Various embodiments of the present invention now will be described morefully hereinafter with reference to the accompanying drawings, in whichsome, but not all embodiments of the inventions are shown. Indeed, theseinventions may be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will satisfy applicablelegal requirements. The term “or” is used herein in both the alternativeand conjunctive sense, unless otherwise indicated. Like numbers refer tolike elements throughout.

According to various embodiments, a cable integrated solar invertersystem is provided for converting DC power received from photovoltaiccells into AC power suitable for supply to a power grid. The cableintegrated solar inverter system can be used in conjunction with avariety of photovoltaic power systems, including systems in bothcommercial and residential environments. As an example, FIG. 1A shows abuilding structure 5 having a photovoltaic power system interconnectedwith an AC power grid 9. In the illustrated embodiment, the photovoltaicpower system includes a photovoltaic solar array 10. In particular, thesolar array 10 is configured to generate power in combination with awind turbine 20, which can be stored in an energy storage unit (e.g.,comprised of the illustrated battery array 22 and a fuel cell array 24).In the illustrated embodiment, a fuel operated generator 26 is alsoprovided for emergency operation.

The photovoltaic solar array 10 of FIG. 1A comprises a plurality ofphotovoltaic solar panels 11-18. Although the building structure 5 hasbeen shown as a residential building structure, it should be understoodthat the photovoltaic solar array 10 may be mounted on virtually anytype of building structure or on a ground surface. In one embodiment,each of the plurality of photovoltaic solar panels 11-18 is made from amultiplicity of photovoltaic solar cells 19. Each of the photovoltaicsolar cells 19 may generate, for example, approximately 0.5 volts. Whenconnected in series—parallel, the cells 19 together may provide, forexample, approximately 300 watts of power at 30 volts. In someinstances, individual photovoltaic solar panels 11-18 are mounted onequatorial mounts (not shown) for following the movement of the sunthroughout the day.

FIG. 1B shows a schematic diagram of a cable integrated solar invertersystem 102 according to one embodiment. In the illustrated embodiment,the cable integrated solar inverter system 101 includes a trunk cable102, a plurality of distributed power converters 206, each distributedalong the trunk cable 102, and a grid interface unit 106. As shown inFIG. 1B, the power converters 206 are each electrically connected to oneof a plurality of photovoltaic modules 11-18. The power converters 206are also connected to one another in series via the trunk cable 102. Asexplained in greater detail herein, the power converters 206 are eachconfigured to function as a half-sine wave power converter. Inoperation, the power converters 206 convert DC power received from thephotovoltaic modules 11-18 into rectified half-sine wave signals, whichare added and delivered to the grid interface unit 106 via the trunkcable 102. The grid interface unit 106 then converts the signalsreceived from the power converters 206 into a full AC sine-wave powersignal suitable for delivery to a power grid.

As shown in FIG. 1B, the power converters are integrated into the trunkcable 102, which connects the power converters 206 in series. As anexample, in one embodiment the trunk cable 102 comprises a 30-ampererated AC cable. The trunk cable 102 extends between the integrated powerconverters 206, which can be embedded, enclosed, or otherwise integratedinto the cable in a variety of ways.

In some embodiments, trunk cable ends 110 a and 110 b are both connectedto grid interface unit 106. In other embodiments, trunk cable end 110 bis connected to grid interface unit 106 and terminal 110 a isterminated.

In some embodiments, grid interface unit 106 includes elements that arenot required to be in close proximity to photovoltaic modules 11-18. Forexample, the grid interface unit 106 may include fault detectionsystems, monitoring systems, synchronization systems, unfoldingcircuitry, interface and communication circuitry and/or the like. In oneembodiment, the grid interface unit 106 supplies the grid with AC power.The distributed power converter system is configured for converting DCPower (e.g., produced by solar panels and/or photovoltaic panels) intoAC power suitable for supplying a power grid. The power converters 206are connected in series to one another and each power converter isconnected to a photovoltaic panel.

As one example, FIG. 2A shows an isometric view of a cable integrateddistributed power converter according to one embodiment. In theillustrated embodiment, to facilitate ease of maintenance andreplacement of faulty devices, the power converter 206 comprises aremovable cartridge 211 that can be selectively removed from the trunkcable 102. In particular, as shown in FIG. 2A, the power convertercartridge 211 is configured to be selectively secured to a housing 208.According to various embodiments, the housing 208 may be constructedfrom a thermally conductive material (e.g., metals, metal alloys,thermally conductive plastic, a combination of plastics and metalsand/or the like). For example, the housing 208 may be constructed fromthermally conductive plastic and include a metal heat-sink. Likewise,the power converter cartridge 211 may be constructed from similarthermally conductive materials and in similar manner.

As shown in FIG. 2A, the housing 208 is a generally rigid memberdefining a generally horizontal, flat base and a central recessed area214 configured for receiving the removable power converter cartridge211. Opposing ends of the housing 208 are attached to the trunk cable102. For example, in the illustrated embodiment, the trunk cable 102 issecured to the housing 208 in a weather-proof manner (e.g., viaweather-proof rubber grommets 213 a, 213 b, or by overmolding thehousing onto the trunk cable).

In the illustrated embodiment, the power converter cartridge 211 definesa generally rigid exterior shell configured for insertion into therecessed area 214 of the housing 208. As explained in greater detailbelow, the power converter's electronic components are sealed within thecartridge 211 and thereby shielded from outside weather. As shown inFIG. 2A, the power converter cartridge 211 includes positive andnegative terminals 202, 204 configured for connection to thephotovoltaic modules 11-18. In particular, the terminals 202, 204 enablethe power converter 206 to receive DC power from the photovoltaicmodules 11-18, which the power converter 206 then converts into arectified half-sine signal as described below.

The power converter cartridge 211 also includes connection terminals 210b on its opposing ends for providing an electrical connection betweenthe power converter cartridge 211 its housing 208. As shown in FIG. 2A,the housing 208 includes corresponding connection terminals 210 a, whichprotrude inwardly into the housing's recessed area 214. As such, thepower converter cartridge's connector terminals 210 b are conductivecavities configured for reviving the housing's connector terminals 210a. In the illustrated embodiment, the connecters 210 a and 210 b helpsecure the power converter cartridge 211 in housing 208. Moreover, inthe illustrated embodiment, the power converter cartridge 211 andhousing 208 each include two connecters. However, in various otherembodiments, the power converter cartridge 211 and housing 208 include asingle connector or multiple connecters (e.g., three connecters, fourconnecters, five connecters and/or the like). In further embodiments,the connecters may comprise flat electrical contacts that are merely incontact with one another.

According to certain embodiments, the electrical connectors areconfigured to provide dedicated electrical connections between the powerconverter 206, adjacent power converters 206, and the above-describedgrid interface unit 106. For example, in one embodiment, the electricalconnectors comprise a power connection line, a fault detection line, anda synchronization line between the power converters 206 and gridinterface unit 106.

As noted above, the power converter cartridge is configured to beremovably secured within the housing 208. FIG. 2B shows the powerconverter cartridge 211 secured within housing 208. According to variousembodiments, the housing 208 may include a latch or other fasteningdevice (not shown) for securing and/or releasing the power convertercartridge. In other embodiments, the shape of the housing 208facilitates the power converter cartridge 211 snapping in place wheninserted into the housing.

In certain embodiments, power converters 206 may include a lightemitting diode (LED) to indicate that status of the power converter. Forexample, the LED may display a green light if the power converter isproperly secured in place. Alternatively, the LED may display a redlight if the power converter is loose and/or not properly secured withinhousing 208. Additionally, power converters 206 may be configured tomeasure the amount of power being outputted by the power converter anddisplay the measurement as an LED output. For example, the LED beconfigured to flash up to 10 times where each flash represents apercentage of measured power output compared to total power output. Forexample, 2 flashes corresponds to a measurement of 20 percent of totalpower output up and 9 flashes corresponds to 90 percent of total poweroutput for the power converter

As explained below, the power converter 206 electronics are containedwithin the power converter cartridge 211. In certain embodiments, whenthe power converter cartridge 211 is removed from the housing 208, ajumper cartridge may be inserted to bridge the gap left by the powerconverter cartridge. In other embodiments, a set of connectors may beprovided to connect the power converter to the cable. The connectorsleft on the cable after removal of the power converter can then bedirectly connected together, thereby connecting the gap left fromremoval of the converter. Moreover, when a power converter 206 isdetermined to be faulty, it may be easily replaced by inserting a newpower converter cartridge 211 into a respective housing 208.

As will be appreciated from the description herein, in one embodiment,each of the power converters 206 shown in FIG. 1B may take theconfiguration shown and described with respect to FIGS. 2A and 2B. Inparticular, the cable integrated solar inverter system may comprisenumerous power converters 206 (e.g., 10 power converters) spread evenlyalong a length of the trunk cable 102 in order to facilitate ease ofconnection to photovoltaic modules. However, as will be appreciated fromthe description herein, in various other embodiments the powerconverters 206 may not be integrated directly into the trunk cable 102.In such embodiments, the power converters may be configured such thatindividual sections of trunk cable can be removably secured to eachpower converter 206. In this configuration, the trunk cable 102 iscomprised of numerous sections of cable.

As another example, FIG. 3 shows an isometric view of a cable integratedpower converter according to another embodiment. In the illustratedembodiment of FIG. 3, the power converter's electronics are containedwithin a housing 311, which may be sealed for weather proofing. Thepower converter's housing includes positive and negative terminals 305,308, which are configured to enable the power converter to be connectedto a photovoltaic module. The housing 311 also includes terminals 302 a,302 b, and 302 c disposed on its opposing ends. The terminals 302 a, 302b, and 302 c configured to provide a detachable electrical connectionwith the trunk cable 102 at both ends of the housing 311. For example,as shown in FIG. 3, the trunk cable 102 includes correspondingconnection terminals 304 a, 304 b, and 304 c. The opposite end of thepower converter 206 (obstructed from view in FIG. 3) is connected to asecond section of the trunk cable 102 in the same fashion.

In one embodiment, the corresponding pairs of power converter and trunkcable connection terminals 302 a/304 a; 302 b/304 b; and 302 c/304 c areconfigured to provide dedication electrical connections between thepower converter 206, adjacent power converters 206, and theabove-described grid interface unit 106. For example, in one embodiment,the terminals 302 a/304 a connect a power connection line, the terminals302 b/304 b connect a fault detection line, and the terminals 302 c/304c connect a synchronization line, each of which is established betweenthe power converters 206 and grid interface unit 106. As will beappreciated from the description herein, the terminals 302 a/304 a, 302b/304 b, and 302 c/304 c may be integrated into a single multi-pininterface.

With respect to the illustrated embodiment of FIG. 3, a faulty powerconverter 206 may be replaced by disconnecting the trunk cable 102 fromthe power converter 206 and connecting the trunk cable 102 to a newpower converter 206 of the same type. As a result, the practicaloperation of the cabling system of FIG. 3 is similar to the operationdescribed above with reference to FIG. 2A and FIG. 2B.

The illustrated housing 311 may be an expanded housing configured tohouse two or more power converters 206. In this embodiment, each of theconnections 304 a-304 c would be repeated such that each of the two ormore power converters 206 has a dedicated connection to the trunk cable.In some examples of this embodiments, the two or more power converters206 in the expanded housing would share a controller.

As yet another example, FIGS. 4A and 4B show an overhead view of a cableintegrated power converter according to another embodiment. In theillustrated embodiment of FIG. 4A, the power converter's electronics arecontained within a power converter cartridge 411 configured for beingremovably secured between brackets 404 and 402 disposed at ends ofsections of the trunk cable 102. According to various embodiments, thepower converter cartridge 411 is configured for being connected viapositive and negative terminals (not shown) to a photovoltaic module11-18 as described above.

Each of brackets 404 and 402 is configured for removable attachment toopposite ends of the power converter cartridge 411. For example, bracket404 includes protruding elements 404 a and 404 b for removably attachingtrunk cable 102 to the power converter cartridge 411. Similarly, bracket402 includes protruding elements 402 a and 402 b for removably attachingtrunk cable 102 to the power converter cartridge 411. As shown in FIGS.4A and 4B, the shape of the edges of brackets 404 and 402 correspond tothe shape of the edges of the power converter cartridge 411. Insertingthe power converter cartridge 411 into bracket 402 secures the powerconverter cartridge 411 between elements 402 a and 402 b. Similarly,inserting power converter cartridge 411 into bracket 402 secures thepower converter cartridge 411 between elements 404 a and 404 b. Theprotruding elements 404 a,b; 402 a,b may be configured to partiallysurround and engage the power converter cartridge 411 using a press-fitconfiguration, snap-fit configuration, a latch, a magnetic attachment,or by other suitable means.

FIG. 4A shows the power converter cartridge 411 disconnected from trunkcable 102, while FIG. 4B shows the power converter cartridge 411connected and secured to the trunk cable 102. As illustrated in thefigures, the trunk cable 102 is electrically connected to the brackets404 and 402 (e.g., with weather-proof rubber grommets 413 a, 413 b tosecure the connection). The brackets 404, 402 are configured forelectrically connecting the power converter cartridge 411 to the trunkcable 102 via projecting terminals 406 a and 408 a. In particular, theprojecting terminals 406 a and 408 a are configured for insertion intocorresponding terminals 406 b and 408 b of the power converter cartridge411. As can be appreciated form FIGS. 4A and 4B, inserting the terminals406 a into the terminals 406 b establishes an electrical connectionbetween a first section of the trunk cable 102 and the power convertercartridge 411, while inserting the terminals 408 a into the terminals408 b establishes an electrical connection between a second section ofthe trunk cable 102 and the power converter cartridge 411. In addition,the connected terminals 408 and 406 help secure the power convertercartridge 411 to the brackets 402, 404 and trunk cable 102.

In one embodiment, the corresponding pairs of power converter cartridge411 and trunk cable 102 connection terminals 408 a/408 b, and 406 a/406b are configured to provide dedicated electrical connections between thepower converter 206, adjacent power converters 206, and theabove-described grid interface unit 106. For example, in one embodiment,the three prongs of the electrical connections 408 a,b and 406 a,b shownin FIGS. 4A and 4B represent a power connection line, a fault detectionline, and a synchronization line, respectively. However, as willappreciated from the description herein, the connection terminals may beintegrated into a single multi-pin interface or any other suitableelectrical connection interface. Indeed, in various other embodiments,the power converter cartridge 411 and housing 208 may include a singleconnector or multiple connecters (e.g., four connecters, five connectersand/or the like). Additionally, in further embodiments, the connectersmay comprise flat electrical contacts that are merely in contact withone another.

FIG. 5A shows a schematic circuit diagram of a cable integrated solarinverter system according to one embodiment. As indicated in FIG. 5a ,the photovoltaic modules 11-18 are each connected to a respective powerconverter 206. As will be appreciated from the description herein, eachpower converter 206 may be a cable integrated power converter having anyof the various configuration described herein (e.g., as shown in FIGS.2A-4B). In the illustrated embodiment, the power converters 206 areconnected to one another in series and are synchronized to ensure thatthe output of each power converter 206 is in-sync with the otherconverters 206 (as described in relation to FIG. 8A-B). The output ofeach power converter 206 is added to produce a power converter output510, as indicated in FIG. 5A. In one embodiment, the output of eachpower converter is similar to the output 510. The synchronizationensures that when the output of each converter is added, the wave form510 is maintained.

In one embodiment, the DC power from a photovoltaic module 11-18 isdelivered to a buck converter within each power converter 206. Asexplained in greater detail below, the buck converter is configured toproduce a half-sine wave (or rectified wave). The buck converters eachutilize pulse width modulation and an output filter to produce ahalf-sine wave from the input DC power signal. As the power converters206 are connected in series, the output voltages are added to produce ahalf-sine wave at the end of the trunk cable that is the sum of thevoltage output from each power converter. Notably, this configurationallows the use of smaller components that are rated for lower voltagethan would ordinarily be required to convert or invert the same amountof power. For example, this configuration may utilize smaller componentsrated to block only the voltage on the photovoltaic modules 11-18. Inother words, the components do not necessarily have to be rated to blockthe entire voltage of the string, which allows for the use of lower costcomponents (e.g., in comparison to a design requiring a higher rating).

According to various embodiments, the power converters 206 areconfigured to independently control their output to draw maximum powerfrom their respective photovoltaic modules while also maintaining asmooth half-sine wave shape (e.g., sine wave without significantelectrical fluctuations or spikes). FIG. 6 shows a circuit diagram for apower converter 206 according to one embodiment. The boxes marked inphantom within FIG. 6 show different circuit operation steps associatedwith control system 600. The voltage from each photovoltaic module isfirst measured and filtered, and the difference between the voltage atthe panel and the known maximum power point voltage (Vmp) is calculatedcircuit operation step 602. For example, at circuit operation step 602,the control system 600 receives a voltage reading from the photovoltaicmodule and then subtracts the received voltage from the voltagedetermined from a maximum power point tracking (MPPT) routine. Theoutput from circuit operation step 602 is then fed into aproportional-integral (PI) controller as shown in circuit operation step604.

The PI controller multiplies the determined difference (e.g., error) bya first constant gain and a second gain multiplied by an integral termthat increases over time at circuit operation step 604. In turn, firstand second products above are then added. The added sum above is thenmultiplied by a rectified sine-wave to modulate the sum into a rectifiedsine wave shape at circuit operation step 606. The product of thismultiplication is then compared to the actual output current flowingthrough the string of power converters and the trunk cable circuitoperation step 606. For example, the actual current flow through thestring of power converters is subtracted from the current determined atcircuit operation step 606. The difference between these two signalsrepresents an error signal, which is fed into a second PI controller atcircuit operation step 608.

The second PI controller is generally similar to the PI controllerdescribed above. The output of the second PI controller is then fed intothe power width modulation (PWM) software routine, which continuouslymodulates switching transistors in the power converters to generate asmooth half-sine output at circuit operation step 610. The two levelfiltering process optimizes the voltage and current independently andsimultaneously. This ensures that the control system achieves the smoothdesirable power results in a fast and an efficient manner. Once thecontrol system 600 achieves a steady state the power output remainsoptimized. When unexpected events that affect the power output occur thesystem will automatically adjust in a manner similar to the describedabove. As will be appreciated from the description herein, a controlsystem similar to exemplary control system 600 may be implemented ineach power converter (e.g., power converter cartridges 211, 311, and411).

Referring back to FIG. 5A, a blocking diode 506 is connected in serieswith the power converters 206 to prevent electrical signals frompropagating towards the power converters 206 and photovoltaic modules.The power converter output 510 is then transmitted to an unfoldingbridge 504 for conversion to a pure or a full AC signal.

In the illustrated embodiment of FIG. 5A, the unfolding bridge 504 ishoused within the grid interface unit 106 (shown in FIG. 1B). Generally,the unfolding bridge is configured to convert the output signal 510generated collectively by the power converters 206 into an AC powersignal (e.g., suitable for supply to a power grid). In particular, asshown in FIG. 5B, the unfolding bridge 504 is configured to convert thehalf-sine wave 510 output by the power converters 206 into a full sinewave 512 (illustrated as the unfolding bridge output). The unfoldingbridge output 512 is then transmitted back to a power grid 508.

According to one embodiment, the circuitry within the grid interfaceunit 106 functions as an H-bridge configured to reverse the polarity ofthe power converter output signal 510 on alternate sine pulses.Reversing the polarity, in turn, converts the rectified half-sine waveshape 510 into a pure sine wave shape 512 suitable for delivery to apower grid. It is understood that the term “sine wave” may be used torefer to a cosine wave, a shifted sine wave, a shifted cosine wave, anysinusoidal signal, any sinusoidal combination of signals or the like.Similarly, the term “half-sine wave” may refer to a half-cosine wave, ashifted half-sine wave, a shifted half-cosine wave, any half-sinusoidalsignal, half-sinusoidal combination of signals or the like.

Referring back to the illustrated embodiment of FIG. 1B, the gridinterface unit 106 (including its unfolding circuitry) is locatedremotely from the power converters 206 and the photovoltaic modules11-18. For example, while the power converters 206 and photovoltaicmodules 11-18 may be located in an outdoor environment, the gridinterface unit 106 may be located in an indoor environment or securedwithin a separate weather resistant housing.

FIG. 7 shows a schematic circuit diagram of a cable integrated solarinverter system according to a different embodiment. In this illustratedembodiment, the power converters 206 collectively construct an output510, similar to FIG. 5A. However, in this embodiment a first powerconverter may produce the base portion of output 510, while a secondpower converter produces a middle portion of output 510 and a thirdpower converter produces a top portion of output 510. The output fromthe 3 power converters may be added to produce power converter output510. For example, in order to construct the rectified (half-sine) wave510, a first power converter 206 generates base portion 510 c of therectified (half-sine) wave, a second power converter 206 generatesmiddle portion 510 b of the rectified (half-sine) wave, and a thirdpower converter 206 generates top portion 510 a of the rectified(half-sine) wave. In the illustrated embodiment, the power converters206 are connected to one another in series and are synchronized toensure that the output of each power converter 206 is in-sync with theother converters 206. Therefore the signals 510 a, 510 b and 510 c areadded to one another to create the rectified (half-sine) wave 510. Inthe illustrated embodiment, the converters output 510 is constructed bythree different converters 206. However, in other embodiments theconverters output 510 may be constructed by more or less powerconverters 206. For example, the output 510 may be constructed by 2, 5,or 10 power converters 206.

Although the photovoltaic system 7 has been set described as a singlephase 120 volt 60 hertz electrical system, it should be understood thatthe present invention is suitable for use with other types of electricalsystems including 240 volt 50-60 hertz grid systems. In addition, itshould be understood that the present invention is suitable for withother types of renewable energy sources such as windmills, water wheels,geothermal and is suitable for with other types energy storages devicessuch as fuel cells, capacitor banks and/or the like.

According to various embodiments, communication and synchronization databetween the grid interface unit 106 and power converters 206, may besent as signals along one combined synchronization and communicationswire in the trunk cable 102. In general, in order for the systemdescribed in the above to function correctly, the output power 510 mustbe correctly synchronized to the grid as described in relation to FIGS.5-7. In various embodiments, the grid interface unit 106 is configuredto synchronize the output power 510 to the grid. For example, in oneembodiment, the grid interface unit 106 is configured to monitor thegrid 508 and detect the zero crossing point in grid 508's AC voltage.The grid interface unit 106 then broadcasts a synchronization signal inthe form of a square wave on a dedicated synchronization wire, in trunkcable 102, to each of the power converters 206 connected to the trunkcable. Each of the power converters 206 are configured to synchronizeeach of their individual outputs to output 510 by monitoring theincoming synchronization signal square wave broadcast by grid interfaceunit 106 on the dedicated synchronization wire in trunk cable 102. Thecurrent or voltage on the communications wire is sourced by the gridinterface unit 106 and can vary between a high and low state. Each powerconverter 206 is configured to detect the zero crossing point of grid508 by sensing a transition from high to low (or alternatively low tohigh) in the synchronization signal. As each power converter 206receives the synchronization signal, each power converter is configuredto begin creating the half sine voltage signal in synchronization withthe other power converters and grid 508.

In addition to the synchronization among the power converters, therealso is a requirement to exchange serial data or command data betweenthe power converters 206 and the grid interface unit 106. In someembodiments, this command data is used for system monitoring and controland may include requests for status of the power converters 206,addressing commands of the power converters 206, requests for voltage,current, or power levels being measured by the power converters 206,and/or fault or shutdown commands. In some embodiments this data istransferred through a dedicated serial communications line, in additionto the line used for synchronization. However, it is advantageous tocombine the synchronization line and the serial communications line intoone line or wire, to reduce the wiring needs and overall system cost.

In one embodiment, the serial communication signal and thesynchronization signal are combined into a single signal on one wire byreserving certain periods of time for the synchronization signal, withthe remainder of the time reserved for serial data transmission.

FIG. 8A depicts an exemplary combined synchronization and serialcommunication electrical signal 802 broadcast on a combinedsynchronization and communication line. For example, grid 508 mayoperate at a nominal 60 Hz rate, thus the zero crossing signal happenstwice per cycle at approximate 8.33 millisecond intervals. Thesynchronization signal produced by grid interface unit 106 will thusswitch between high and low at approximately every 8.33 millisecond atas depicted at times 804. The power converters 206 will observe guardbands 808 around the zero crossing transition during which no data canbe sent down the line. For example, this guard band can be approximately2 milliseconds around each zero crossing. During bands 808 surroundingeach transition in the signal, the power converters 206 are configuredto monitor the combined serial communication and synchronization signalto measure the timing of each transition. This transition is used tosynchronize the power converters 206 to the power line to produce asynchronized output, such as output 510. Outside of the guard bands 808,in communication time 806, the grid interface unit 106 sends otherrelevant or command data to the power converters 206.

In one embodiment, the synchronization signal is included as part of acommunication packet. For example the grid interface unit may beconfigured to utilize a standard Universal Asynchronous ReceiverTransmitter (UART) Non Return to Zero Encoding (NRZ) physical layer anda link layer carrying a packet of information.

FIG. 8B depicts a serial representation of an exemplary combinedsynchronization and serial communication electrical communication packet820 utilizing a standard UART.

For example, a first zero crossing synchronization happens at the firstedge of the Start Bit 822, during the change from Idle to Start Bit. Insome examples, a microcontroller I/O port in each power converter 206 isconfigured both as an external edge triggered interrupt and a as a UARTReceiver Port. This allows the first edge change, Start Bit 822, ofcombined packet 820 to the power converters 206, to be used as asynchronization trigger for the power converters 206 to start outputtinga rectified sine wave. For example, an external Edge Interrupt ServiceRoutine (ISR) located in each power converter 206 may begin the processof the rectified sine wave building. Furthermore, because themicrocontroller I/O port is also configured as a UART Receiver, allbytes 824, corresponding to the command data from the grid interfaceunit to the power converters 206, can also be received.

Furthermore, inside of the ISR, the edge interrupt capability isdisabled for a certain period of times, such as approximately 8 ms inthe case of a 120 Hz half sine waves, so that all the bytes of thepacket can arrive without falsely triggering zero crossing signaling. Insome examples, the packet of information is smaller than the period ofthe rectified sine wave. This results in an idle time allowing the powerconvert 206 to enable the edge interrupt again or to allow the reservedtime for synchronization signal. In some examples, to respond tomessages sent by the grid interface unit 106, the power converters 206can respond by either sending pulses of current or voltage along thesame wire at a designated period within the cycle, or across a differentwire in trunk cable 102.

While this specification contains many specific embodiment details,these should not be construed as limitations on the scope of anyinventions described herein, but rather as descriptions of featuresspecific to particular embodiments of particular inventions. Certainfeatures that are described herein in the context of separateembodiments can also be implemented in combination in a singleembodiment. Conversely, various features that are described in thecontext of a single embodiment can also be implemented in multipleembodiments separately or in any suitable sub-combination. Moreover,although features may be described above as acting in certaincombinations, one or more features from a combination can in some casesbe excised from the combination, and the combination may be directed toa sub-combination or variation of a sub-combination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. In certain circumstances, multitasking and parallel processingmay be advantageous. Moreover, the separation of various systemcomponents in the embodiments described above should not be understoodas requiring such separation in all embodiments, and it should beunderstood that the described program components and systems cangenerally be integrated together in a single product or packaged intomultiple products.

Thus, particular embodiments of the subject matter have been described.Other embodiments are within the scope of the specification above. Insome cases, the actions recited in the specification can be performed ina different order and still achieve desirable results. In addition, theprocesses depicted in the accompanying figures do not necessarilyrequire the particular order shown, or sequential order, to achievedesirable results. In certain embodiments, multitasking and parallelprocessing may be advantageous.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the application.

That which is claimed:
 1. A solar inverter system for converting directcurrent (DC) power from a plurality of photovoltaic modules intoalternating current (AC) power, the solar inverter system comprising: aplurality of distributed power converters configured for being connectedin series, wherein each of the power converters is configured for beingelectrically connected to at least one photovoltaic module; and a gridinterface unit configured to be electrically connected to the powerconverters and to a power grid; wherein the grid interface is connectedto each of the power converters by a trunk cable; wherein each of theplurality of power converters comprises a detachable converter cartridgeand a housing attached to the trunk cable, the housing being secured toat least a portion of the trunk cable and the detachable convertercartridge being configured for removable insertion into the housing,wherein the housing comprises one or more housing terminals configuredto be electrically connected to the detachable converter cartridgeinserted within the housing and the trunk cable; and wherein at least aportion of at least one of the power converters is removably attached tothe trunk cable.
 2. The solar inverter system of claim 1, wherein eachpower converter housing is embedded in the trunk cable.
 3. The solarinverter system of claim 1, wherein the detachable converter cartridgecomprises one or more converter element terminals configured to receivea DC power signal from the at least one photovoltaic module.
 4. Thesolar inverter system of claim 1, wherein the trunk cable comprises aplurality of trunk cable portions, each trunk cable portion beingremovably secured to one or more of the plurality of power converters.5. The solar inverter system of claim 1, further comprising weatherproofhousing for housing one or more of the plurality of power converters. 6.The solar inverter system of claim 1, wherein the grid interface unit islocated remotely from the plurality of power converters.
 7. The solarinverter system of claim 1, further comprising a plurality ofphotovoltaic modules, wherein each of the distributed power convertersis configured for being electrically connected to a respectivephotovoltaic module of the plurality of photovoltaic modules, andwherein each of the power converters is configured for converting a DCpower signal received from the respective photovoltaic module into arectified sine wave signal.
 8. The solar inverter system of claim 7,wherein the photovoltaic modules of the plurality of photovoltaicmodules are not connected to one another in series.
 9. The solarinverter system of claim 1, wherein the power converters each comprise abuck converter.
 10. The solar inverter system of claim 1, wherein thegrid interface unit comprises an unfolding bridge for conversion fromthe rectified signal to the AC signal for supply to the power grid. 11.The solar inverter system of claim 1, wherein each of the distributedpower converters is configured for converting a DC power signal receivedfrom the at least one photovoltaic module into a rectified sine wavesignal, and wherein the grid interface unit is configured to convert therectified sine wave signal produced by the plurality of converters to anAC signal for supply to the power grid.
 12. The solar inverter system ofclaim 11, wherein the rectified sine wave signal comprises a half-sinewave.
 13. The solar inverter system of claim 12, wherein the half-sinewave comprises a half-wave of one of at least a sinusoidal waveincluding a sine wave, a cosine wave, a shifted sine wave, or a shiftedcosine wave.
 14. The solar inverter system of claim 1, wherein each ofthe power converters is configured for converting a DC power signalreceived from the respective photovoltaic module into a half-sine wavesignal.
 15. The solar inverter system of claim 1, wherein the gridinterface unit is configured to synchronize the power converters andcommunicate with the power converters through a combined synchronizationand communication line in the trunk cable.
 16. The solar inverter systemof claim 1, wherein the power converters are each configured to producean individual part of a rectified sine wave signal, such that whencombined the individual parts form a full rectified sine wave signal.17. The solar inverter system of claim 1, wherein the power convertersare synchronized by a combined synchronization and communication signalproduced by the grid interface unit, wherein the combined signalincludes communication bits.
 18. The solar inverter system of claim 1,wherein the grid interface unit further comprises a fault detectionsystem, a monitoring system, a synchronization system, and acommunication system.
 19. The solar inverter system of claim 1, furthercomprising a blocking diode connected in series with the plurality ofpower converters, such that electrical signals are prevented frompropagating towards the plurality of power converters and the connectedphotovoltaic modules.